Insulation-Retaining Sheet Having Integral Vapor-Retarding Membrane

ABSTRACT

The present disclosure relates generally to an insulation-retaining sheet, e.g., for blown-in insulation, that includes an integral vapor-retarding membrane. In one aspect, the disclosure provides an insulation-retaining sheet including a sheet of mesh having an air permeability of at least 200 cfm per square foot; and one or more strips of vapor-retarding membrane, the one or more strips of vapor-retarding membrane being laminated to the sheet of mesh, the first side edge each of the strips of vapor-retarding membrane extending to the first side edge of the sheet of mesh, the second side edge each of the strips of vapor-retarding membrane extending to the second side edge of the sheet of mesh, wherein the insulation-retaining sheet has a plurality of open zones extending laterally from the first side edge of the sheet of mesh to the second side edge of the sheet of mesh in which no vapor-retarding membrane is laminated to the mesh.

BACKGROUND OF THE DISCLOSURE

This application is a continuation of U.S. patent application Ser. No.16/142512, filed Sep. 26, 2018, which claims the benefit of priority ofU.S. Provisional Patent Application No. 62/563340, filed Sep. 26, 2017,each of which is hereby incorporated herein by reference in itsentirety.

BACKGROUND OF THE DISCLOSURE 1. Field of the Disclosure

The present disclosure relates generally to building products. Thepresent disclosure relates more particularly to an insulation-retainingsheet, e.g., for blown-in insulation, that includes an integralvapor-retarding membrane.

2. Technical Background

Conventional insulation for walls and ceilings of buildings is providedin the form of thick batts of fiberglass-based insulation material.These batts of insulation are typically installed between the framingmembers of the wall or ceiling, with a vapor-retarding membrane beinginstalled to cover them in a separate operation. A wallboard enclosesthe insulation and the vapor-retarding membrane in the interior of thewall or ceiling.

However, in recent years, blow-in insulation has found increasing use inthe insulation of such cavities. Blown-in insulation is provided as aloose fluff of material, with air pressure being used to convey it intoa cavity that is to be insulated. The framing members of a building aretypically themselves unable to form a cavity in which insulation can beblown; at the stage of insulation, while the outer sheeting and framingmembers can close off five of six faces of a rectangular cavity, theface of the cavity oriented toward the building interior remains open.To form an insulation cavity, a sheet of mesh is installed across theopen face of the cavity, with an opening left for a tube to convey theinsulation. As air pressure is used to blow the insulation into thecavity, the material of the mesh typically has to be open enough toallow air to escape the cavity. If the material enclosing the cavitydoes not allow air to escape the cavity at a sufficiently high rate, theresulting backpressure can cause that material to burst. In a typicalinstallation, after the cavity is filled with insulation, avapor-retarding membrane is installed over the mesh to provide the wallwith a desired performance with respect to water vapor.

These conventional methods for insulating these walls can be difficultand time consuming. There remains a need for improved methods andmaterials for use with blown-in insulation materials.

SUMMARY OF THE DISCLOSURE

In one aspect, the present disclosure provides an insulation-retainingsheet having a top edge and an opposed bottom edge, and a first sideedge and an opposed second side edge, the insulation-retaining sheetincluding:

-   -   a sheet of mesh having an air permeability of at least 200 cfm        per square foot, a top edge and an opposed bottom edge, and a        first side edge and an opposed second side edge; and    -   one or more strips of vapor-retarding membrane, each of the one        or more strips of vapor retarding membrane each having a top        edge and an opposed bottom edge, and a first side edge and an        opposed second side edge, the one or more strips of        vapor-retarding membrane being laminated to the sheet of mesh,        the first side edge each of the strips of vapor-retarding        membrane extending to the first side edge of the sheet of mesh,        the second side edge each of the strips of vapor-retarding        membrane extending to the second side edge of the sheet of mesh,    -   wherein the insulation-retaining sheet has a plurality of open        zones extending laterally from the first side edge of the sheet        of mesh to the second side edge of the sheet of mesh in which no        vapor-retarding membrane is laminated to the mesh.

In another aspect, the present disclosure provides a method ofinsulating one or more building cavities, the method including:

-   -   providing one or more insulation cavities, each having an open        face defined at least in part by a plurality of building        members;    -   substantially enclosing the one or more insulation cavities with        an insulation-retaining sheet as described herein by affixing        the insulation-retaining sheet to the plurality of building        members; and    -   blowing insulation into the one or more cavities.        Such a method can further include, after blowing the insulation        into the one or more cavities, covering one or more of (e.g.,        each of) the open zones.

In another aspect, the present disclosure provides an insulated buildingcavity, the insulated building cavity including

-   -   a cavity closed off on one face by an insulation-retaining sheet        as described herein; and    -   loose-fill insulation disposed in the cavity.

Additional aspects of the disclosure will be evident from the disclosureherein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a furtherunderstanding of the methods and devices of the disclosure, and areincorporated in and constitute a part of this specification. Thedrawings are not necessarily to scale, and sizes of various elements maybe distorted for clarity. The drawings illustrate one or moreembodiment(s) of the disclosure, and together with the description serveto explain the principles and operation of the disclosure.

FIG. 1 is a schematic plan view of an insulation-retaining sheetaccording to one embodiment of the disclosure;

FIG. 2 is a schematic cross-sectional view of the insulation-retainingsheet of FIG. 1,

FIG. 3 is a schematic plan view of an insulation-retaining sheetaccording to another embodiment of the disclosure;

FIG. 4 is a schematic plan view of an insulation-retaining sheetaccording to another embodiment of the disclosure;

FIG. 5 is a schematic plan view of an insulation-retaining sheetaccording to another embodiment of the disclosure;

FIGS. 6 and 7 are schematic cross-sectional views of theinsulation-retaining sheet of FIG. 5;

FIG. 8 is a schematic cross-sectional view of an insulation-retainingsheet according to another embodiment of the disclosure;

FIG. 9 is a partial schematic cross-sectional view of aninsulation-retaining sheet according to another embodiment of thedisclosure;

FIG. 10 is a schematic plan view, and

FIG. 11 is a schematic cross-sectional view of a partially-built walldescribed with respect to a method of one embodiment of the disclosure;

FIG. 12 is a schematic plan view, and

FIG. 13 is a schematic cross-sectional view of a the wall of FIGS. 10and 11 with an insulation-retaining sheet installed;

FIG. 14 is a schematic plan view, and

FIG. 15 is a schematic cross-sectional view of a the wall of FIGS. 12and 13 in which the open zones are covered;

FIG. 16 is a schematic plan view of a building cavity with aninsulation-retaining sheet installed thereon, according to oneembodiment of the disclosure; and

FIGS. 17-19 are schematic plan views of particular examples of theinsulation-retaining sheets as described herein.

DETAILED DESCRIPTION

The present inventors have determined that an insulation-retaining sheetthat includes an integral vapor-retarding membrane, when configured asdescribed herein, can allow for blown-in insulation to be installed in awall cavity without the formation of an undesirably high backpressure,yet remove the need for the installation of a separate vapor-retainingmembrane. Accordingly, the methods and materials described herein cansubstantially simplify the insulation and vapor protection of buildingwalls and ceilings, by requiring one less sheet installation operation.This is especially significant in that installation of sheet materialsalong a large wall or ceiling surface can be an unwieldy process due tothe size of the surface and the flexibility of the materials. Theinsulation-retaining sheets described herein allow one less suchoperation, which represents a significant savings in time and manpower.

One aspect of the disclosure is an insulation-retaining sheet. Oneembodiment of such an insulation-retaining sheet is shown in schematicplan view in FIG. 1, and in schematic cross-sectional view in FIG. 2.Insulation-retaining sheet 100 has a top edge 103 and an opposed bottomedge 104, and a first side edge 105 and an opposed second side edge 106.The insulation-retaining sheet 100 includes a sheet of mesh 110 havingan air permeability of at least 200 cfm (cubic feet per minute) persquare foot (e.g., at least 300 cfm per square foot) as measured by ASTMD737-961 (i.e., without being laminated to vapor-retarding membrane).The sheet of mesh 110 has a top edge 113 and an opposed bottom edge 114,and a first side edge 115 and an opposed second side edge 116.Insulation-retaining sheet 100 also includes one or more (here, two)strips of vapor-retarding membrane 120 laminated to the sheet of mesh110. The first side edge 125 of each of the strips of vapor retardingmembrane extends to the first side edge 115 of the sheet of mesh, andthe second side edge 126 of each of the strips of vapor retardingmembrane extends to the first side edge 116 of the sheet of mesh.

Notably, the insulation-retaining sheet has a plurality of open zones130 extending laterally from the first side edge 115 of the mesh to thesecond side edge of the mesh 116. In these open zones, novapor-retarding membrane is laminated to the mesh. These open zones areconfigured such that air can readily escape through the mesh, so thatwhen the insulation-retaining sheet installed to enclose a wall orceiling, the open zones can prevent pressure buildup in the cavity fromair used to blow insulation into the cavity.

In certain desirable embodiments, and as shown in FIG. 1, the first sideedge of the mesh extends to the first side edge of theinsulation-retaining sheet, and the second side edge of the mesh extendsto the second side edge of the insulation-retaining sheet. In certainsuch desirable embodiments, the first side edge of each of the strips ofvapor retarding membrane extends to the first side edge of theinsulation-retaining sheet, and the second side edge of each of thestrips of vapor retarding membrane extends to the second side edge ofthe insulation-retaining sheet. Such embodiments can be especiallydesirable, in that they can enable the person of ordinary skill in theart to use roll-to-roll processes to manufacture them, and in that theycan result in long lengths of insulation-retaining sheet that can bearbitrarily cut to desired lengths by a user for installation in abuilding. In cases where the sheet of mesh does not extend to both sideedges of the insulation-retaining sheet, it desirably extends at least90%, or at least 95% of the distance between the side edges of theinsulation-retaining sheet.

Similarly, in certain desirable embodiments, and as shown in FIG. 1, thetop edge of the mesh extends to the top edge of the insulation-retainingsheet, and the bottom edge of the mesh extends to the bottom edge of theinsulation-retaining sheet. In cases where the sheet of mesh does notextend to both top and bottom edges of the insulation-retaining sheet,it desirably extends at least 90%, or at least 95% of the distancebetween the side edges of the insulation-retaining sheet.

As the person of ordinary skill in the art will appreciate, the materialof the sheet of mesh allows significant amounts of air to flow throughit. As described above, the sheet of mesh has an air permeability of atleast 200 cfm per square foot. In certain embodiments as otherwisedescribed herein, the sheet of mesh has an air permeability of at least250 cfm per square foot or at least 300 cfm per square foot, forexample, at least 400 cfm per square foot, or even at least 450 cfm persquare foot. Air permeabilities of the sheet of mesh as described hereinare measured according to ASTM D737-961, on the mesh material itself(i.e., not as configured in the insulation-retaining sheet). Use of asheet of mesh with a high enough airflow can allow the open zones of theinsulation-retaining sheet to pass enough air such that there is not anundesirably high degree of pressure buildup during blow-in ofinsulation, even though much of the area of the sheet of mesh is coveredby the laminated vapor-retarding membrane.

As the person of ordinary skill in the art will appreciate from thepresent disclosure, the sheet of mesh can be formed from many materials.For example, in certain embodiments as otherwise described herein, themesh is a fabric mesh, such as a woven fabric mesh or a non-woven fabricmesh. The mesh can be formed from, for example, a polymer such aspolyethylene or polypropylene. In other embodiments, the mesh is formedfrom glass, textile, cotton, hemp, nylon, or similar materials (e.g., infiber form, woven or non-woven). The mesh desirably has a pore size thatis small enough such that significant amounts of blown-in insulation donot escape through the fabric. For example, in certain embodiments, themesh has an average pore size no greater than 1 mm, e.g., no greaterthan 500 microns. The person of ordinary skill in the art willappreciate that many conventional fabrics used conventionally inblown-in insulation systems can be used as the sheet of mesh in theconstruction of the insulation-retaining sheets as described herein. Onesuitable material for use as a fabric mesh is OPTIMA® Fabric, availablefrom CertainTeed Corporation. Others are available under a variety oftradenames from a variety of suppliers, such as INSULWEB, manufacturedby Hanes Engineered Materials.

Similarly, the person of ordinary skill in the art will appreciate fromthe present disclosure that the vapor-retarding membrane can take a widevariety of forms. A wide variety of vapor-retarding membranes areavailable to the person of ordinary skill in the art. For example, incertain embodiments as otherwise described herein, the vapor-retardingmembrane has a water vapor permeance of no more than about 1 Perm at 25%relative humidity, as tested by ASTM E96 at 23° C. In certainembodiments as otherwise described herein, the vapor-retarding membranehas a water vapor permeance of at least 2 perms, e.g., in the range of4-15 perms, or in the range of 6-12 perms at 75% relative humidity astested by ASTM E96 at 23° C. In certain such embodiments, the vaporretarding membrane has not only a water vapor permeance of no more thanabout 1 Perm at 25% relative humidity, but also a water vapor permeanceof at least 2 perms, e.g., in the range of 4-15 perms, e.g., in therange of 6-12 perms at 75% relative humidity, all as tested by ASTM E96at 23° C. Thus, the vapor retarding membrane can be a so-called “smartvapor retarder,” i.e., being configured to retard diffusion of watervapor under dry conditions but allow diffusion of water vapor underespecially humid conditions. In certain such embodiments, the vaporretarding membrane also has one or more of a) a water vapor permeance ofno more than 5 perms, e.g., no more than 2.5 perms or less at 45%relative humidity, and b) a water vapor permeance of at least about 5Perms (e.g., at least about 8 Perms, or at least about 12 Perms, or atleast about 15 Perms, or at least about 20 Perms) at 95% relativehumidity, both as tested by ASTM E96 at 23° C. For example, in certainembodiments as otherwise described herein, the membrane has a watervapor permeance no more than 1 perm at 25% relative humidity; a watervapor permeance of no more than 5 perms, or even 2.5 perms or less at45% relative humidity; and a water vapor permeance in a range of from 6perms to 12 perms at 75% relative humidity; and a water vapor permeanceof at least 20 perms at 95% relative humidity, all as tested by ASTM E96at 23° C.

Water vapor permeance values as described herein are measured using theASTM E96 “desiccant method” (i.e., dry cup) or the ASTM E96 “water vapormethod” (i.e., wet cup), as noted below. Specifically, samples weresealed over either dry cups filled with desiccant to achieve the 25% and45% average relative humidity conditions or sealed over wet cups filledwith deionized water to achieve the 75% and 95% RH conditions. The cupswere placed in a humidity chamber at either 50% relative humidity (for25% or 75% average relative humidity conditions) or 90% relativehumidity (for the 45% or 95% average relative humidity conditions). The“relative humidity” of a given test is taken as the average of theenvironment in the cup (i.e., 0% or 100%) and the environment in thechamber (i.e., 50% or 90%), based on the assumption that the sampleitself will be at a humidity in between the two values. So a dry cuptest performed in a 90% relative humidity chamber will be at a nominalrelative humidity value of 45%. Similarly, 25% relative humidity valuesare determined in a dry cup measurement at a chamber humidity of 50%;75% relative humidity values are determined in a wet cup measurement ata chamber humidity of 50%; and 95% relative humidity values aredetermined in a wet cup measurement at a chamber humidity of 90%.Experiments are otherwise performed as described in ASTM E96, which ishereby incorporated herein by reference in its entirety.

One suitable such membrane is the MemBrain™ Continuous Air Barrier &Smart Vapor Retarder membrane available from CertainTeed Corporation.Others include, for example, products available from ISOVER under thetradename Vario, such as Vario Duplex, Vario Triplex, Vario Xtra andVario XtraSafe. Other suitable membranes are disclosed in U.S. PatentApplication Publication no. 2016/0185994, U.S. Patent ApplicationPublication no. 2015/0090126, U.S. Pat. No. 6,808,772, and U.S.Provisional Patent Applications Nos. 62/527596 and 62/527609, each ofwhich is hereby incorporated by reference in its entirety for allpurposes, and especially for their description of suitable membranes.

The vapor-retarding membrane can be formed from a variety of materials.For example, in certain embodiments as otherwise described herein, thevapor-retarding membrane is a polymer sheet, such as a polymer laminate.Suitable polymers include, for example, polyethylene, polypropylene,nylon (e.g., nylon-6) and poly(vinyl chloride). In other embodiments asotherwise described herein, the vapor-retarding membrane is a sheet,such as a non-woven fabric or kraft paper, having a vapor-retardingcoating or laminate formed thereon. The person of ordinary skill in theart will appreciate that many conventional vapor retarding membranesused conventionally in building systems can be used as thevapor-retarding membrane in the construction of the insulation-retainingsheets as described herein.

The vapor-retarding membrane can also be provided as a cured coatinglayer that is applied directly to the sheet of mesh in one or morestrips. Such a cured coating can completely fill the void spaces of themesh in the areas where it is applied, and thereby provide an effectivecoating for retarding water vapor. In certain embodiments as otherwisedescribed herein, the coating can penetrate into the substrate by atleast about 1%, at least about 5%, or even at least about 10% of thethickness of the mesh. In certain embodiments as otherwise describedherein, the barrier layer can penetrate into the mesh by no more than95%, no more than 90%, or even no more than 85% of the thickness of themesh. In other embodiments, the mesh can be completely saturated suchthat a continuous layer of the coating is disposed on both majorsurfaces of the mesh. The person of ordinary skill in the art canprovide coated sheets of mesh based on the disclosure herein, especiallyin conjunction with the description provided in U.S. Patent ApplicationPublication no. 2016/0185994, and U.S. Provisional Patent ApplicationsNos. 62/527596 and 62/527609.

The person of ordinary skill in the art will appreciate that the one ormore strips of vapor-retarding membrane can be provided on the sheet ofmesh in a variety of manners. For example, in some embodiments, a layerof adhesive affixes the strip(s) of vapor-retarding membrane to thesheet of mesh. The person of ordinary skill in the art will select anadhesive that is compatible with the materials of the mesh and of themembrane, and will take into account the vapor-retarding properties ofthe adhesive itself. The person of ordinary skill in the art can selectan amount and type of adhesive that provides the overall laminate (i.e.,the vapor retarding membrane laminated to the sheet of mesh and anyintervening adhesive) with desirable vapor permeance behavior inconjunction with acceptable adhesion. In other embodiments, thematerials are such that they can make a tenacious bond throughheat-pressing; in such cases, there may be an intimate bond between thematerials of the mesh and of the membrane. The vapor-retarding membranecan in some embodiments be provided as a cured coating; in such cases,the strip(s) of vapor-retarding membrane can be applied to the sheet ofmesh by providing a suitable coating composition on the sheet of mesh,and allowing the coating composition to cure to provide the coating.Coating compositions are described, for example, in U.S. PatentApplication Publication no. 2016/0185994, and U.S. Provisional PatentApplication No. 62/527596, each of which is hereby incorporated hereinby reference in its entirety.

The presence of the sheet of mesh and any adhesive may change the vaporpermeance behavior of the laminate from that of the vapor-retardingmembrane below. However, the person of ordinary skill in the art will beable to account for this in selection of materials. In certain desirableembodiments as otherwise described herein, the insulation-retainingsheet has, in the laminated zones thereof, a water vapor permeance of nomore than about 1 Perm at 25% relative humidity, as tested by ASTM E96at 23° C. In certain embodiments as otherwise described herein, theinsulation-retaining sheet has, in the laminated zones thereof, a watervapor permeance of no more than 5 perms, e.g., no more than 2.5 perms orless at 45% relative humidity, and b) a water vapor perm rating of atleast 2 perms, e.g., in the range of 4-15 perms, or in the range of 6-12perms at 75% relative humidity as tested by ASTM E96 at 23° C. Incertain such embodiments, the insulation-retaining sheet has, in thelaminated zones thereof, not only a water vapor permeance of no morethan about 1 Perm at 25% relative humidity, but also a water vaporpermeance of no more than 5 perms, e.g., no more than 2.5 perms or lessat 45% relative humidity, and b) a water vapor perm rating of at least 2perms, e.g., in the range of 4-15 perms, or in the range of 6-12 permsat 75% relative humidity as tested by ASTM E96 at 23° C. Thus, theinsulation retaining sheet can function as a so-called “smart vaporretarder,” i.e., being configured to retard diffusion of water vaporunder dry conditions but allow diffusion of water vapor under especiallyhumid conditions. In certain such embodiments, the insulation-retainingsheet also has, in the laminated zones thereof, has one or more of a) awater vapor permeance of no more than 5 perms, e.g., no more than 2.5perms or less at 45% relative humidity, and b) a water vapor perm ratingof in the range of at least about 5 Perms (e.g., at least about 8 Perms,or at least about 12 Perms, or at least about 15 Perms, or at leastabout 20 Perms) at 95% relative humidity as tested by ASTM E96 at 23° C.For example, in certain embodiments as otherwise described herein, themembrane has a water vapor permeance no more than 1 perm at 25% relativehumidity; a water vapor permeance of no more than 5 perms, or even 2.5perms or less at 45% relative humidity; a water vapor permeance in arange of from 6 perms to 12 perms at 75% relative humidity; and a watervapor permeance of at least 20 perms at 95% relative humidity, all astested by ASTM E96 at 23° C.

And, in certain desirable embodiments as otherwise described herein, theinsulation-retaining sheet has, in the laminated zones thereof, anywater vapor permeance value as described above with respect to thevapor-retarding membrane.

As the person of ordinary skill in the art will appreciate from thepresent disclosure, the insulation-retaining sheet can be configured ina variety of ways to provide open zones as described herein. Forexample, in certain embodiments of the insulation-retaining sheets asotherwise described herein, there are a plurality of the strips ofvapor-retarding membrane. For example, in the embodiment of FIGS. 1 and2, there are two strips of vapor-retarding membrane. But in otherembodiments, a different number of strips of vapor-retarding membranecan be used. Use of more strips of vapor-retarding membrane can beadvantageous in some situations to allow for more open zones to beformed on the insulation-retaining sheet, and thus allow for pressure toescape a cavity to be insulated at more points along its height. Forexample, the embodiment of the insulation-retaining sheet 300 shown inschematic plan view in FIG. 3, there are four strips of vapor retardingmembrane 320, forming five open zones 330. But provision of more openzones can also, in some embodiments, require more open zones to becovered after the blowing in of insulation, as described in more detailbelow. In certain embodiments, the number of strips of vapor-retardingmembrane is in the range of 2-10, for example, in the range of 2-8, or2-6, or 2-4, or 3-10, or 3-8, or 3-6, or 5-10, or 5-8.

And in other embodiments of the insulation-retaining sheets as otherwisedescribed herein, there is only a single strip of vapor-retardingmembrane. For example, the embodiment of the insulation-retaining sheet400 shown in schematic plan view in FIG. 4, there is a lone strip ofvapor retarding membrane 420, forming two open zones, one along the topedge of the insulation-retaining sheet and the other along the bottomedge of the insulation-retaining sheet.

As the person of ordinary skill in the art will appreciate, the one ormore open zones can be configured in a variety of ways. For example, incertain embodiments of the insulation-retaining sheets as otherwisedescribed herein, the one or more open zones include a top open zoneextending along the top edge of the insulation-retaining membrane and abottom open zone extending along the bottom edge of theinsulation-retaining membrane, for example, as shown in the embodimentsof FIGS. 1-4. In certain such embodiments, these are the only open zonesof the insulation-retaining membrane, for example, as shown in FIG. 4.Of course, in other embodiments, there is an open zone along the topedge of the insulation-retaining sheet but not along its bottom edge, oralong the bottom edge of the insulation-retaining sheet but not alongits top edge. Use of open zones at the top edge and/or the bottom edgeof the insulation-retaining membrane can be advantageous, in that it canhelp to ensure that the corners of the cavity are filled by blown-ininsulation.

In certain embodiments of the insulation-retaining sheets as otherwisedescribed herein, the one or more open zones include one or moreinterior open zones extending across the sheet of mesh between its topedge and its bottom edge, for example, as shown in the embodiments ofFIGS. 1-3. Use of open zones in an interior section of theinsulation-retaining membrane can be advantageous, in that it can helpto ensure that pressure is relieved throughout the volume of the cavityare during the blowing in of insulation. One or more interior open zonescan be used in combination with, or instead of open zone(s) along thetop edge and/or the bottom edge of the insulation-retaining sheet.

As the person of ordinary skill in the art will appreciate from thepresent disclosure, the insulation-retaining sheet can be configuredwith any number of open zones as described herein. For example, incertain embodiments, the number of open zones is in the range of 2-10.For example, in the embodiment of FIGS. 1 and 2, there are three openzones. In the embodiment of FIG. 4, there are six open zones. And in theembodiment of FIG. 3, there are two open zones. As noted above, the useof more open zones can allow for pressure to escape a cavity to beinsulated at more points along its height. But provision of more openzones can also, in some embodiments, require more open zones to becovered after the blowing in of insulation, as described in more detailbelow. In certain embodiments as otherwise described herein, the numberof open zones of the vapor-retarding membrane is in the range of 2-11,for example, in the range of 2-9, or 2-7, or 2-5, or 3-11, or 3-9, or3-7, or 5-11, or 5-9. For example, in certain embodiments as otherwisedescribed herein, the insulation-retaining sheet has two open zones, orthree open zones, or four open zones.

In certain embodiments, each of the strips of vapor-retarding membraneis laminated to the sheet of mesh substantially throughout its height.This configuration is shown in the schematic cross-sectional view ofFIG. 2. Here, the one or more open zones are not covered by any loosematerial. In certain such embodiments, the open zones can be covered bystrips of material, such as tape or strips of vapor-retarding membrane,after insulation is blown into a cavity, as described in more detailbelow.

In other embodiments, at least some of the strips of vapor retardingmembrane are configured to form flaps over the one or more open zones.Such flaps will not interfere substantially with air escaping throughthe mesh in the one or more open zones. After insulation is blown into acavity, as described in more detail below, each flap can be affixed tothe mesh or to another strip of vapor retarding membrane to cover theopen zones.

Accordingly, in certain embodiments of the insulation-retaining sheetsas otherwise described herein, the one or more strips of vapor retardingmembrane comprise one or more first strips of vapor retarding membrane,each having a top zone in a top-most portion of the first strip, the topzone extending from the first side edge to the second side edge of thefirst strip, the top zone being laminated to the sheet of mesh, and abottom zone in a bottom-most portion of the first strip adjacent the topportion of the first strip, the bottom zone extending from the firstside edge to the second side edge of the first strip, the bottom zonenot being affixed to the sheet of mesh, the bottom zone forming a flaphaving a bottom edge, a first side edge and an opposed second side edge.Such an embodiment is shown in schematic plan view in FIG. 5, andschematic cross-sectional views in FIGS. 6 and 7. Here,insulation-retaining sheet 500 has a first strip of vapor retardingmembrane 540, which has a top zone 547 and a bottom zone 548. The darkline 550 indicates an adhesive bonding the top zone 547 of the firststrip 540 to the sheet of mesh 510. The bottom zone 548 of the firststrip 540 is not affixed to the mesh; an open zone 530 is formed by thearea of mesh to which the first strip is not affixed. Accordingly, itforms a flap 560 having a bottom edge 564, a first side edge 561 and anopposed second side edge 562. The flap 560 is free to lift away from themesh when air blows through the membrane (as shown by the arrows in FIG.7), thereby not significantly affecting the flow of air through the openzone 530.

Of course, the person of ordinary skill in the art will appreciate thatmultiple first strips may be used in the insulation-retaining sheets asdescribed herein. While the embodiment shown in FIGS. 5-7 has only asingle first strip, in other embodiments an insulation-retaining sheetas otherwise described herein can have two first strips, three firststrips, or four first strips. In still other embodiments, aninsulation-retaining sheet as otherwise described herein can have in therange of 2-10 first strips, e.g., in the range of 2-9, or 2-7, or 2-5,or 3-11, or 3-9, or 3-7, or 5-11, or 5-9.

In certain embodiments of the insulation-retaining sheets as otherwisedescribed herein, the one or more strips of vapor retarding membraneinclude not only one or more first strips as described above, but alsoone or more second strips of vapor-retarding membrane, each of the oneor more second strips of vapor retarding membrane being laminated to thesheet of mesh substantially throughout its height. For example, theinsulation-retaining sheet 500 of FIGS. 5-7 includes a second strip 528of vapor retarding membrane, laminated to the sheet of meshsubstantially throughout its height, as indicated by shown by the darkline 551 indicating an adhesive bonding the second strip 520 to thesheet of mesh 510.

In certain embodiments of the insulation-retaining sheets as otherwisedescribed herein, one or more of the flaps (e.g., each of the one ormore flaps) substantially covers the open zone defined thereby. Forexample, in the embodiment of FIGS. 5-7, the flap substantially exactlycovers the open zone. That is, in the embodiment of FIGS. 5-7, the flapdoes not substantially overlap another strip of vapor-retardingmembrane.

In certain embodiments of the insulation-retaining sheets as otherwisedescribed herein, one or more of the flaps (e.g., each of the one ormore flaps) substantially overlaps a neighboring strip ofvapor-retarding membrane. One such embodiment is shown in schematiccross-sectional view in FIG. 8. In insulation-retaining sheet 800, thereare two first strips 840 and 841 of vapor-retarding membrane, with theirtop zones laminated to the sheet of mesh and their bottom zonesunaffixed to the sheet of mesh 810. There is also a second strip 820 ofvapor-retarding membrane laminated to the sheet of mesh. Notably, theflap 860 formed by first strip 840, substantially overlaps its downwardneighboring strip of vapor-retarding membrane, first strip 841. And theflap 861 formed by first strip 841 substantially overlaps its downwardneighboring strip of vapor-retarding membrane, second strip 820. In suchembodiments, after insulation is blown in, the flap can be affixed withtape or an adhesive to its neighboring strip of vapor-retardingmembrane.

For example, in certain such embodiments, one or more of (e.g., each of)the overlapping flaps has a strip of adhesive, for example, with aremovable liner, disposed along its bottom edge facing the sheet ofmesh. In such embodiments, the flap can freely lift away from the meshof the open zone during blowing in of insulation, then afterwards aninstaller can adhere the flap to a neighboring strip of vapor-retardingmembrane, e.g., by peeling the liner away to expose the adhesive. Suchan embodiment is shown in partial schematic cross-sectional view in FIG.9. Here, in the left-hand image, flap 960 has a strip of adhesive 955disposed along its bottom edge (shown folded up). A removable liner 956covers the strip of adhesive. An installer can remove the removableliner and affix the flap to the neighboring strip of vapor-retardingmembrane, as shown in the right-hand image.

While the flaps are shown as being configured to cover adownwardly-situated open zone in FIGS. 6-9, the person of ordinary skillin the art will appreciate that the insulation-retaining sheet canalternatively be configured so that they cover an upwardly-situated openzone. In such case, when installed, the flaps can fall away from theopen zone entirely, but be affixed to cover the open zone afterinsulation is blown in.

The person of ordinary skill in the art will select the relative heightsof the top (laminated) zone and the bottom (unaffixed) zone of eachfirst strip, in conjunction with the heights of any second strips, toprovide a desired area of open zone(s) to the insulation-retainingmembrane. For example, in certain embodiments, in each first strip, theheight of the top zone is at least the height of the bottom zone, e.g.,at least 1.5 times, at least 2 times, or at least 3 times the height ofthe bottom zone. In certain embodiments, in each first strip, the heightof the top zone is no more than 20 times the height of the bottom zone,e.g., no more than 15 times, or no more than 10 times the height of thebottom zone.

The height of the bottom zone of each first strip of vapor-retardingmembrane can help to determine the height of the corresponding open zoneof the insulation-retaining membrane. For example, in certainembodiments as otherwise described herein, in each first strip ofmaterial, the bottom zone is at least 2 inches in height. For example,in certain such embodiments, the bottom zone of each first strip ofvapor retarding membrane is at least 4 inches, or even at least 8 inchesin height. In certain such embodiments, the bottom zone of each firststrip of vapor retarding membrane is in the range of 2-25 inches, or2-16 inches, or 4-25 inches, or 4-16 inches, or 8-25 inches, or 8-16inches in height.

The strips of vapor-retarding membrane can have a variety of heights. Incertain embodiments of the insulation-retaining sheets as otherwisedescribed herein, each of the strips of vapor retarding membrane has aheight of at least 4 inches, at least 8 inches, at least 15 inches, oreven at least 25 inches. For example, in certain embodiments, each ofthe strips of vapor-retarding membrane has a height of in the range of 4inches to 180 inches, e.g., in the range of 4-160 inches, or 4-128inches, or 4-104 inches, or 4-76 inches, or 4-66 inches, or 4-54 inches,or 4-42 inches, or 4-30 inches, or 8-180 inches, or 8-160 inches, or8-128 inches, or 8-104 inches, or 8-76 inches, or 8-66 inches, or 8-54inches, or 8-42 inches, or 8-30 inches, or 18-180 inches, or 18-160inches, or 18-128 inches, or 18-104 inches, or 18-76 inches, or 18-66inches, or 18-54 inches, or 18-42 inches, or 30-180 inches, or 30-160inches, or 30-128 inches, or 30-104 inches, or 30-76 inches, or 30-66inches, or 30-54 inches, or 30-42 inches, or 42-180 inches, or 42-160inches, or 42-128 inches, or 42-104 inches, or 42-76 inches, or 42-66inches, or 42-54 inches, or 54-180 inches, or 54-160 inches, or 54-128inches, or 54-104 inches, or 54-76 inches, or 54-66 inches, or 66-180inches, or 66-160 inches, or 66-128 inches, or 66-104 inches, or 66-76inches, or 76-180 inches, or 76-160 inches, or 76-128 inches, or 76-104inches. In certain embodiments, each strip has a height selected fromabout 12″, about 16″, about 18″, about 24″, about 36″, about 48″, about54″, or about 72″. The person of ordinary skill in the art willappreciate that the various strips of vapor-retarding membrane in agiven insulation-retaining sheet of the disclosure can have differentheights. The person of ordinary skill in the art can combine multiplestrips of desired heights to provide an insulation-retaining sheethaving an overall architecture and overall pattern of open zones. FIGS.17-19 show a few different examples of configurations. In otherexamples, an insulation-retaining sheet seven feet in height having oneor more “flaps” (as described with respect to FIGS. 5-7) can be madewith a 48″ strip and a 36″ strip. Similarly, an insulation-retainingsheet eight feet in height having one or more flaps can be made with two48″ strips; an analogous nine foot high insulation-retaining sheet canbe made with a 48″ strip and a 60″ strip or three 36″ strips; ananalogous ten foot high insulation-retaining sheet can be made with two60″ strips or a 72″ strip and a 48″ strip; an analogous eleven footinsulation-retaining sheet can be made with two 48″ strips and a 36″strip; and an analogous twelve foot high insulation-retaining sheet canbe made with three 48″ strips or four 36″ strips. Other combinationswill be apparent to the person of ordinary skill in the art, and theperson of ordinary skill in the art will take into account the presenceof any open zone(s) not configured to be covered by flaps whencalculating heights of strips to be used in designing a giveninsulation-retaining sheet.

The person of ordinary skill in the art, based on the disclosure herein,will select the heights of the one or more open zones, in conjunctionwith the number of open zones, to provide a desired balance of coverageby vapor-retarding membrane and airflow during blowing in of insulation.Moreover, it can be desirable to keep the height of each open zonerelatively low, in order to simplify the operation of covering up theopen zone(s) after blowing in of insulation. For example, in certainembodiments, each of the open zones has a height in the range of 1-24inches. In certain such embodiments, each of the open zones has a heightin the range of 1-16 inches, or 1-12 inches, or 1-8 inches, or 1-6inches, or 1-4 inches, or 2-24 inches, or 2-16 inches, or 2-12 inches,or 2-8 inches, or 2-6 inches, or 2-4 inches, or 3-24 inches, or 3-16inches, or 3-12 inches, or 3-8 inches, or 3-6 inches, or 6-24 inches, or6-16 inches, or 6-12 inches. The person of ordinary skill in the artwill appreciate that the various open zones of a giveninsulation-retaining sheet of the disclosure can have different heights.

The person of ordinary skill in the art, based on the disclosure herein,will select the overall area of the one or more open zones, i.e., as afraction of area of the insulation-retaining sheet, to provide a desiredbalance of coverage by vapor-retarding membrane and airflow duringblowing in of insulation. In certain embodiments as otherwise describedherein, at least 5% (e.g., at least 7%, at least 10%, at least 15%, atleast 25% or even at least 35%) of the area of the insulation-retainingsheet is open zones. In certain embodiments as otherwise describedherein, no more than 50% (e.g., no more than 40%, no more than 30%, oreven no more than 20%) of the area of the insulation-retaining sheet isopen zones.

Advantageously, the insulation-retaining sheets of the presentdisclosure can be made in a variety of heights, suitable for enclosingcavities in variety of sizes of walls, ceilings and floors. For example,in certain embodiments, an insulation-retaining sheet as otherwisedescribed herein has a height (measured from top edge to bottom edge) ofat least 48 inches, at least 56 inches, at least 70 inches, or even atleast 80 inches. For example, in certain such embodiments, aninsulation-retaining sheet as otherwise described herein has a height inthe range of 48 inches to 200 inches, e.g., in the range of 48-150inches, or 48-105 inches, or 48-80 inches, or 56-200 inches, or 56-150inches, or 56-105 inches, or 56-80 inches, or 70-200 inches, or 70-150inches, or 70-105 inches, or 80-200 inches, or 80-150 inches, or 80-105inches. In certain embodiments, the insulation-retaining sheet has aheight selected from about 72″, about 84″, about 96″, about 108″, about120″, about 132″, and about 144″.

Similarly, the insulation-retaining sheets of the present disclosure canbe made in variety of lengths. Notably, they can be made long enough tospan multiple framing members, e.g., multiple rafters, multiple floorjoists, or multiple wall studs, and thus can, when installed, enclose aplurality of cavities into which insulation can be filled. For example,in certain embodiments, an insulation-retaining sheet as otherwisedescribed herein has a length (measured from the first side edge to thesecond side edge) of at least 4 feet, at least 8 feet, at least 12 feet,or even at least 16 feet. In certain such embodiments, aninsulation-retaining sheet as otherwise described herein has a length inthe range of 4 feet to 300 feet, for example, 4 feet to 150 feet, or 4feet to 100 feet, or 4 feet to 60 feet, or 4 feet to 40 feet, or 4 feetto 32 feet, or 4 feet to 24 feet, or 4 feet to 16 feet, or 8 feet to 300feet, or 8 feet to 150 feet, or 8 feet to 100 feet, or 8 feet to 60feet, or 8 feet to 40 feet, or 8 feet to 32 feet, or 8 feet to 24 feet,or 16 feet to 300 feet, or 16 feet to 150 feet, or 16 feet to 100 feet,or 16 feet to 60 feet, or 16 feet to 40 feet, or 16 feet to 32 feet.

Notably, the insulation-retaining sheet as described herein can beprovided in the form of a roll. Because in certain embodiments theinsulation-retaining sheet has a substantially uniform cross-sectionalong its length, a roll of material can be provided at any arbitrarylength, with desired lengths of material cut to fit a desired buildingelement.

In certain embodiments, an insulation-retaining sheet as otherwisedescribed herein has one or more apertures formed therein. As the personof ordinary skill in the art will appreciate, in many installations itis desirable for the insulation-retaining sheet to have one or moreapertures to allow a hose or tube to access the cavity for the purposeof delivering the blown-in insulation. The apertures can be in a varietyof shapes, e.g., formed as slits, rectangular holes or rounded holes. Incertain embodiments, the one or more apertures have a longest dimensionin the range of 1 to 6 inches. When a plurality of apertures arepresent, they can be provided in with a regular spacing, e.g., on 16inch centers or on 24 inch centers, to line up with a desired spacing ofcavities (e.g., based on stud or rafter spacing).

In certain desirable embodiments, one or more of the apertures (e.g.,each of the apertures) are formed in one or more open zones of theinsulation-retaining sheets. Advantageously, this avoids forming in themore sensitive vapor-retarding material, and, in many embodiments, theopen zone will be covered after installation, so that separately closingor patching the aperture may not be necessary. This can lead to improvedvapor permeance performance, as tape or patch material may be relativelyimpermeable, and can save labor by not requiring a separate aperturepatching step. But in other embodiments, one or more of the apertures(e.g., each of the apertures) are formed in areas of the insulationretaining sheet in which vapor-retarding membrane is laminated to thesheet of mesh.

While these apertures can be made at the time of installation, it can insome circumstances be advantageous to provide them as part of theinsulation-retaining sheet product itself. Accordingly, in certainembodiments, an insulation-retaining sheet as described herein has theone or more apertures formed therein before it is installed over abuilding cavity, e.g., during the manufacturing process.

As the person of ordinary skill in the art will appreciate, theinsulation-retaining sheets described herein can be useful in theinsulation of cavities in buildings, such as in walls, ceilings andfloors. For example, a cavity in a wall can be defined between thesurfaces of the outer sheeting, an upper plate, a lower plate, and twowall studs. A cavity in a ceiling can be defined between a roof deck, aneave strut, a crest or peak strut, and two adjacent rafters. In allcases, one face of the cavity is closed off by an insulation-retainingsheet according to the disclosure. Accordingly, another aspect of thedisclosure is a method of insulating one or more insulation cavities.The method includes providing one or more insulation cavities, e.g., ona wall, a ceiling, or a floor, each of the one or more cavities havingan open face defined at least in part by a plurality of buildingmembers; substantially enclosing the one or more wall cavities withinsulation-retaining sheet as described herein by affixing theinsulation-retaining sheet to the plurality of framing members; andblowing insulation into the one or more cavities.

One such embodiment is shown in FIGS. 10-15. FIG. 10 is a schematic planview, and FIG. 11 is a schematic cross-sectional view of apartially-built wall 1080 having an upper plate 1081, an lower plate1082, and a plurality of studs 1083. An exterior sheeting 1084 isaffixed to the backs of the framing elements. These building elementsdefine a plurality of (here, seven) wall cavities 1085, each having anopen face 1086.

The wall cavities 1085 can then be substantially enclosed with aninsulation-retaining sheet as described here, by affixing theinsulation-retaining sheet to the building members. FIG. 12 is aschematic plan view, and FIG. 13 is a schematic cross-sectional view ofthe wall 1080 of FIGS. 10 and 11 with the insulation-retaining sheet1000 installed. In the embodiment of FIGS. 12 and 13, theinsulation-retaining sheet 1000, having strips of vapor retardingmaterial 1020 and open zones 1030, is affixed to substantially all ofthe building members surrounding the open face of the cavity. In theembodiment shown in FIGS. 12 and 13, staples are used to affix theinsulation-retaining sheet; the person of ordinary skill in the art willappreciate that the insulation-retaining sheet can be affixed in manyways, for example, using other fasteners (e.g., nails, tacks or pins) orby use of adhesives, for example, glues, pressure-sensitive adhesives,water-based, solvent based, silicones, acrylics, caulks, etc. Tape canbe used to hold the insulation-retaining sheet, for example, temporarilywhile it is being affixed in some other manner. The insulation-retainingsheet is desirably affixed to the perimeter of the open facesufficiently that blown-in insulation cannot escape from the interface.The person of ordinary skill in the art will use conventional methodsfor affixing mesh sheets for retaining blown-in insulation in thepractice of this step of the method.

Insulation can then be blown into the cavities. The person of ordinaryskill in the art can use conventional techniques to blow insulation intothe cavities. For example, the insulation can be blown into each of theone or more cavities through an aperture in the insulation-retainingsheet. The person of ordinary skill in the art can form an aperture inthe insulation-retaining sheet in each cavity, to provide access for thehose or tube that conducts the blown-in insulation into the cavity.Alternatively, as described above, the insulation-retaining sheet canalready be provided with the necessary apertures. Apertures 1090 areshown (in the form of slits) formed in the central open zone, one foreach cavity 1085. As described above, during the blowing in of theinsulation, pressure can escape each cavity through the one or more openzones. The person of ordinary skill in the art will blow in theinsulation at a rate and at a pressure at which the open zone(s)insulation-retaining sheet can effectively allow air to escape toprevent an undesirable degree of pressure buildup.

In certain desirable embodiments, one or more of (e.g., each of) theopen zones are covered after the blowing in of insulation. For example,in certain embodiments, one or more of the open zones (e.g., each openzone) is covered with an adhesive tape. In certain embodiments, one ormore of the open zones is covered with a separate strip ofvapor-retarding membrane, which can be the same or different type ofmembrane as that of the insulation-retaining sheet. This is shown in therespective schematic plan and schematic cross-sectional views of FIGS.14 and 15. Here, after insulation 1075 is blown in, separate strips ofvapor-retarding membrane 1080 are affixed to the insulation-retainingsheet to cover the open zones 1030. As the person of ordinary skill inthe art will appreciate, the separate strip(s) of vapor-retardingmembrane can be affixed in a variety of ways. For example, fasteners canbe used, such as staples, nails, tacks and pins (e.g., into framingmembers). A variety of adhesives can also or alternatively be used, forexample, glues, pressure-sensitive adhesives, water-based, solventbased, silicones, acrylics, caulks, etc. Tape can be used to holdstrip(s) of vapor-retarding membrane, either temporarily (e.g., whilebeing affixed in some other manner) or permanently. And the person ofordinary skill in the art will appreciate that other materials, such asvapor blocking membrane, kraft paper, or other sheet materials can beused to cover the open zone(s); the person of ordinary skill in the artwill understand how the vapor permeance performance of the overall wallwill vary depending on the different materials used. In certain suchembodiments, no separate patching, taping, or otherwise sealing of theaperture is necessary, as described above.

While covering the open zones with separate strips of material doesrepresent another installation step, strips of material are much easierfor a single installer to handle than are sheets the size of an entirewall or ceiling section. Accordingly, use of the insulation-retainingsheet as described herein represents a significant simplification of amethod for installing an insulated cavity.

And, as described above, when the insulation-retaining sheet includesone or more flaps, the covering of the open zone(s) can be performed byaffixing the flaps, either to the underlying sheet of mesh or to aneighboring strip of vapor-retarding membrane, to cover one or more ofthe open zones, as described above. Here, too, the flaps can be affixedin a variety of manners. For example, fasteners can be used, such asstaples, nails, tacks and pins (e.g., into framing members). A varietyof adhesives can also or alternatively be used, for example, glues,pressure-sensitive adhesives, water-based, solvent based, silicones,acrylics, caulks, etc. Tape can be used to hold flaps, eithertemporarily (e.g., while being affixed in some other manner) orpermanently. While this, too, represents another installation step, asthe flaps are already substantially in position, it is simple to affixthem to cover the open zones. Accordingly, use of theinsulation-retaining sheet as described herein represents a significantsimplification of a method for installing an insulated cavity.

Any aperture(s) in the insulation-retaining sheet can be closed, e.g.,with a patch of sheet material or with an adhesive tape. The person ofordinary skill in the art can use conventional techniques to close anysuch apertures. Or, as otherwise described herein, the material used toclose the open zones can be sufficient to close the aperture(s).

As the person of ordinary skill in the art will appreciate based on thepresent disclosure, the covering of the open zone(s) and/or the closingof any apertures can be performed to provide the insulation-retainingsheet with substantial airtightness, so that it can help to provide awall or other building element with substantial airtightness. Forexample, the person of ordinary skill in the art can use tape, caulk, oradhesives in the covering of the open zone(s) and/or close any aperturesin order to substantially improve the airtightness. Theinsulation-retaining sheet can therefore act as an air barrier to impartsubstantial airtightness to an insulated building cavity. Thus, theinsulation-retaining sheets described herein can help an installer tomeet the higher requirements of some building codes for both airtightness and energy efficiency, including the especially stringentrequirements of building codes in areas such as in Europe and Canada.

While the description above focuses on wall cavities, the person ofordinary skill in the art will appreciate that other building cavitiessuch as floor cavities and ceiling cavities can be treated similarly.Thus, the insulation-retaining sheets described herein can also beapplied to the undersides of ceilings or floors, in attic truss andjoist areas, below beams, to the top of studs mounted on slabs orfloors, among other geometries. In such cases, the insulation-retainingsheets can be installed substantially horizontally, above or below acavity (i.e., depending on whether the cavity is part of a floor or aceiling). Moreover, while the description with reference to the figuresfocuses on wall cavities that have their longer dimension extendingvertically, the person of ordinary skill in the art will appreciate thatin some embodiments a wall cavity can be longer in a horizontaldimension than in a vertical.

Moreover, the insulation-retaining sheets can be used in theconstruction of prefabricated building panels, i.e., not already part ofa building structure. In such cases, the cavity can be oriented in anyconvenient direction for fabrication, for example, horizontally (i.e.,with panel laying on a horizontal surface, e.g., of a conveyor belt), orvertically (i.e., with the panel held upright during the fillingprocess).

Moreover, in various embodiments otherwise described herein, theinsulation-retaining sheet is installed against a building cavity suchthat the open zone(s) are oriented horizontally with respect to thebuilding, e.g., with the open zone(s) running across multiple buildingcavities. However, notwithstanding the fact that theinsulation-retaining sheet is described herein as having a “top edge”and a “bottom edge,” the insulation-retaining sheets can in otherembodiments be installed against a building cavity such that the openzone(s) are oriented vertically with respect to the building. In certaindesirable such embodiments, each building cavity over which theinsulation retaining sheet has at least part of at least one open zonedisposed over it. One example is shown in schematic plan view in FIG.16. The wall cavities (similar to those of FIGS. 12 and 13) can besubstantially enclosed with an insulation-retaining sheet 1600 asdescribed here, by affixing the insulation-retaining sheet to thebuilding members. In the embodiment of FIG. 16, the insulation-retainingsheet 1600, having open zones 1630, is affixed to substantially all ofthe building members surrounding the open face of the cavity, such thatat least one open zone is disposed over each cavity. Notably, in thisembodiment, the open zones of the insulation-retaining sheet 1600 runvertically with respect to the wall. Accordingly, the “top edge” and the“bottom edge” of the insulation-retaining sheet are disposed at the leftand right sides of the wall section in the figure, while the first andsecond side edges are disposed at the top and bottom sides of the wallsection in the figure.

Another aspect of the disclosure is an insulated building cavity. Theinsulated building cavity includes a cavity closed off on one face by aninsulation-retaining sheet as described herein, and loose-fillinsulation disposed in the cavity. In certain such embodiments, each ofone or more of the open zones (e.g., each of the open zones) of theinsulation-retaining sheet is covered, e.g., by a flap, by a separatestrip of material, by a separate strip of insulating material, or by astrip of adhesive tape. The insulated building cavity can besubstantially as described above with respect to the methods ofinsulation.

FIGS. 17-19 are three examples of particular designs ofinsulation-retaining sheets according to the disclosure. Both of thesesheets are configured to have one or more flaps, as described above. [Inthe embodiment of FIG. 17, four strips of vapor-retarding membrane,here, MemBrain™ brand vapor-retarding membrane, are laminated to thesheet of mesh, here, OPTIMA® brand insulation retaining fabric. The topthree strips are configured as “first strips” as described above, eachhaving a top zone laminated to the sheet of mesh and a bottom zone notaffixed to the sheet of mesh and forming a flap. The bottom strip isconfigured as a “second strip” as described above, completely laminatedto the sheet of mesh. In the embodiment of FIG. 18, there are only twostrips of material; the top one acting as a “first strip” and forming aflap, and the bottom one acting as a “second strip.” In the embodimentof FIG. 19, there is only one strip of material, acting as a “firststrip.” This configuration is shorter than most conventional walls; itcan be used in combination with a separate vapor-retarding membrane toseal off a wall cavity.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the processes and devicesdescribed here without departing from the scope of the disclosure. Thus,it is intended that the present disclosure cover such modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

Additional embodiments of the disclosure are provided below asenumerated embodiments. These embodiments may be combined in any notlogically-inconsistent manner, as indicated.

Embodiment 1. An insulation-retaining sheet having a top edge and anopposed bottom edge, and a first side edge and an opposed second sideedge, the insulation-retaining sheet comprising:

-   -   a sheet of mesh having an air permeability of at least 200 cfm        per square foot, a top edge and an opposed bottom edge, and a        first side edge and an opposed second side edge; and    -   one or more strips of vapor-retarding membrane, each of the one        or more strips of vapor retarding membrane each having a top        edge and an opposed bottom edge, and a first side edge and an        opposed second side edge, the one or more strips of        vapor-retarding membrane being laminated to the sheet of mesh,        the first side edge each of the strips of vapor-retarding        membrane extending to the first side edge of the sheet of mesh,        the second side edge each of the strips of vapor-retarding        membrane extending to the second side edge of the sheet of mesh,    -   wherein the insulation-retaining sheet has a plurality of open        zones extending laterally from the first side edge of the sheet        of mesh to the second side edge of the sheet of mesh in which no        vapor-retarding membrane is laminated to the mesh.

Embodiment 2. The insulation-retaining sheet according to Embodiment 1,wherein the sheet of mesh has an air permeability of at least 300 cfmper square foot, e.g., at least 350 cfm per square foot, at least 400cfm per square foot, or even at least 450 cfm per square foot.

Embodiment 3. The insulation-retaining sheet according to Embodiment 1or Embodiment 2, wherein the mesh is a fabric mesh.

Embodiment 4. The insulation-retaining sheet according to Embodiment 1or Embodiment 2, wherein the mesh is a non-woven fabric mesh.

Embodiment 5. The insulation-retaining sheet according to any ofEmbodiments 1-4, wherein the vapor-retarding membrane has a water vaporpermeance of no more than about 1 Perm at 25% relative humidity, astested by ASTM E96 at 23° C.

Embodiment 6. The insulation-retaining sheet according to any ofEmbodiments 1-5, wherein the vapor-retarding membrane has a water vaporpermeance in the range of at least 2 perms, e.g., 4-15 perms, e.g., inthe range of 6-12 perms at 75% relative humidity as tested by ASTM E96at 23° C.

Embodiment 7. The insulation-retaining sheet according to any ofEmbodiments 1-6, wherein the vapor retarding membrane has one or more ofa) a water vapor permeance of no more than 5 perms, e.g., no more than2.5 perms or less at 45% relative humidity, and b) a water vaporpermeance of at least about 5 Perms (e.g., at least about 8 Perms, or atleast about 12 Perms, or at least about 15 Perms, or at least about 20Perms) at 95% relative humidity, both as tested by ASTM E96 at 23° C.

Embodiment 8. The insulation-retaining sheet according to any ofEmbodiments 1-7, wherein the vapor-retarding membrane is a polymersheet, e.g., of polyethylene, polypropylene, nylon (e.g., nylon-6) orpoly(vinyl chloride).

Embodiment 9. The insulation-retaining sheet according to any ofEmbodiments 1-7, wherein the vapor-retarding membrane comprises a sheet(e.g., a non-woven fabric) having a vapor-retarding coating formedthereon.

Embodiment 10. The insulation-retaining sheet according to any ofEmbodiments 1-7, wherein the vapor-retarding membrane is a polymerlaminate.

Embodiment 11. The insulation-retaining sheet according to any ofEmbodiments 1-10, comprising a plurality of the strips ofvapor-retarding membrane.

Embodiment 12. The insulation-retaining sheet according to any ofEmbodiments 1-10, comprising in the range of 2-10 strips ofvapor-retarding membrane, e.g., in the range of 2-8, or 2-6, or 2-4, or3-10, or 3-8, or 3-6, or 5-10, or 5-8.

Embodiment 13. The insulation-retaining sheet according to any ofEmbodiments 1-10, comprising a single strip of vapor-retarding membrane.

Embodiment 14. The insulation-retaining sheet according to any ofEmbodiments 1-13, wherein the one or more open zones include a top openzone extending along the top edge of the insulation-retaining membraneand a bottom open zone extending along the bottom edge of theinsulation-retaining membrane.

Embodiment 15. The insulation-retaining sheet according to any ofEmbodiments 1-14, wherein the one or more open zones include one or moreinterior open zones extending across the sheet of mesh between its topedge and its bottom edge.

Embodiment 16. The insulation-retaining sheet according to any ofEmbodiments 1-15, having 2-11 open zones.

Embodiment 17. The insulation-retaining sheet according to anyEmbodiments claims 1-15, having a number of open zones in the range of2-9, or 2-7, or 2-5, or 3-11, or 3-9, or 3-7, or 5-11, or 5-9.

Embodiment 18. The insulation-retaining sheet according to any ofEmbodiments 1-15, having two open zones, or three open zones, or fouropen zones.

Embodiment 19. The insulation-retaining sheet according to any ofEmbodiments 1-18, wherein each of the strips of vapor-retarding membraneis laminated to the sheet of mesh substantially throughout its height.

Embodiment 20. The insulation-retaining sheet according to any ofEmbodiments 1-19, wherein the one or more strips of vapor retardingmembrane comprise one or more first strips of vapor retarding membrane,each having

-   -   a top zone in a top-most portion of the first strip, the top        zone extending from the first side edge to the second side edge        of the first strip, the top zone being laminated to the sheet of        mesh, and    -   a bottom zone in a bottom-most portion of the first strip        adjacent the top portion of the first strip, the bottom zone        extending from the first side edge to the second side edge of        the first strip, the bottom zone not being affixed to the sheet        of mesh, the bottom zone forming a flap having a bottom edge, a        first side edge and an opposed second side edge.

Embodiment 21. The insulation-retaining sheet according to Embodiment20, wherein the one or more strips of vapor retarding membrane furthercomprise one or more second strips of vapor-retarding membrane, each ofthe one or more second strips of vapor retarding membrane, each of theone or more second strips of vapor retarding membrane being laminated tothe sheet of mesh substantially throughout its height.

Embodiment 22. The insulation-retaining sheet according to Embodiment 20or Embodiment 21, wherein one or more of the flaps (e.g., each of theone or more flaps) substantially covers the open zone defined thereby

Embodiment 23. The insulation-retaining sheet according to any ofEmbodiments 20-22, wherein one or more of the flaps (e.g., each of theone of more flaps) substantially overlaps a neighboring strip ofvapor-retarding membrane.

Embodiment 24. The insulation-retaining sheet according to Embodiment23, wherein each of the overlapping flaps has a strip of adhesive (e.g.,with a removable liner) disposed along its bottom edge facing the sheetof mesh.

Embodiment 25. The insulation-retaining sheet according to any ofEmbodiments 20-24, wherein in each first strip, the height of the topzone is at least the height of the bottom zone, e.g., at least 1.5times, at least 2 times, or at least 3 times the height of the bottomzone.

Embodiment 26. The insulation-retaining sheet according to any ofEmbodiments 20-25, wherein in each first strip, the height of the topzone is no more than 20 times the height of the bottom zone, e.g., nomore than 15 times, or no more than 10 times the height of the bottomzone.

Embodiment 27. The insulation-retaining sheet according to any ofEmbodiments 20-26, wherein in each first strip of material, the bottomzone is at least 2 inches in height, e.g., at least 4 inches, at least 8inches, or in the range of 2-25 inches, or 2-16 inches, or 4-25 inches,or 4-16 inches, or 8-25 inches, or 8-16 inches in height.

Embodiment 28. The insulation-retaining sheet according to any ofEmbodiments 1-27, wherein each of the strips of vapor retarding membranehas a height of at least 4 inches, at least 8 inches, at least 15inches, or even at least 25 inches.

Embodiment 29. The insulation-retaining sheet according to any ofEmbodiments 1-27, wherein each of the strips of vapor retarding membranehas a height in the range of 4 inches to 180 inches, e.g., in the rangeof 4-160 inches, or 4-128 inches, or 4-104 inches, or 4-76 inches, or4-66 inches, or 4-54 inches, or 4-42 inches, or 4-30 inches, or 8-180inches, or 8-160 inches, or 8-128 inches, or 8-104 inches, or 8-76inches, or 8-66 inches, or 8-54 inches, or 8-42 inches, or 8-30 inches,or 18-180 inches, or 18-160 inches, or 18-128 inches, or 18-104 inches,or 18-76 inches, or 18-66 inches, or 18-54 inches, or 18-42 inches, or30-180 inches, or 30-160 inches, or 30-128 inches, or 30-104 inches, or30-76 inches, or 30-66 inches, or 30-54 inches, or 30-42 inches, or42-180 inches, or 42-160 inches, or 42-128 inches, or 42-104 inches, or42-76 inches, or 42-66 inches, or 42-54 inches, or 54-180 inches, or54-160 inches, or 54-128 inches, or 54-104 inches, or 54-76 inches, or54-66 inches, or 66-180 inches, or 66-160 inches, or 66-128 inches, or66-104 inches, or 66-76 inches, or 76-180 inches, or 76-160 inches, or76-128 inches, or 76-104 inches.

Embodiment 30. The insulation-retaining sheet according to any ofEmbodiments 1-29, wherein each of the open zones has a height in therange of 1-24 inches.

Embodiment 31. The insulation-retaining sheet according to any ofEmbodiments 1-30, wherein each of the open zones has a height in therange of 1-16 inches, or 1-12 inches, or 1-8 inches, or 1-6 inches, or1-4 inches, or 2-24 inches, or 2-16 inches, or 2-12 inches, or 2-8inches, or 2-6 inches, or 2-4 inches, or 3-24 inches, or 3-16 inches, or3-12 inches, or 3-8 inches, or 3-6 inches, or 6-24 inches, or 6-16inches, or 6-12 inches.

Embodiment 32. The insulation-retaining sheet according to any ofEmbodiments 1-31, wherein at least 5% of the area of theinsulation-retaining sheet is open zones.

Embodiment 33. The insulation-retaining sheet according to any ofEmbodiments 1-31, wherein at least 10% of the area of theinsulation-retaining sheet is open zones.

Embodiment 34. The insulation-retaining sheet according to any ofEmbodiments 1-31, wherein at least 15% of the area of theinsulation-retaining sheet is open zones.

Embodiment 35. The insulation-retaining sheet according to any ofEmbodiments 1-34, wherein no more than 30% of the area of theinsulation-retaining sheet is open zones.

Embodiment 36. The insulation-retaining sheet according to any ofEmbodiments 1-34, wherein no more than 25% of the area of theinsulation-retaining sheet is open zones.

Embodiment 37. The insulation-retaining sheet according to any ofEmbodiments 1-34, wherein no more than 20% of the area of theinsulation-retaining sheet is open zones.

Embodiment 38. The insulation-retaining sheet according to any ofEmbodiments 1-37, having a height of at least 48 inches, for example, atleast 56 inches, at least 70 inches, or at least 85 inches.

Embodiment 39. The insulation-retaining sheet according to any ofEmbodiments 1-37, having a height in the range of 48 inches to 200inches, e.g., in the range of 48-150 inches, or 48-105 inches, or 48-80inches, or 56-200 inches, or 56-150 inches, or 56-105 inches, or 56-80inches, or 70-200 inches, or 70-150 inches, or 70-105 inches, or 85-200inches, or 85-150 inches, or 85-105 inches.

Embodiment 40. The insulation-retaining sheet according to any ofEmbodiments 1-39, having a length in the range of at least 4 feet, atleast 8 feet, at least 12 feet, or even at least 16 feet.

Embodiment 41. The insulation-retaining sheet according to any ofEmbodiments 1-40, having a length in the range of 4 feet to 300 feet.

Embodiment 42. The insulation-retaining sheet according to any ofEmbodiments 1-40, having a length in the range of 4 feet to 150 feet, or4 feet to 100 feet, or 4 feet to 60 feet, or 4 feet to 40 feet, or 4feet to 32 feet, or 4 feet to 24 feet, or 4 feet to 16 feet, or 8 feetto 300 feet, or 8 feet to 150 feet, or 8 feet to 100 feet, or 8 feet to60 feet, or 8 feet to 40 feet, or 8 feet to 32 feet, or 8 feet to 24feet, or 16 feet to 300 feet, or 16 feet to 150 feet, or 16 feet to 100feet, or 16 feet to 60 feet, or 16 feet to 40 feet, or 16 feet to 32feet.

Embodiment 43. The insulation-retaining sheet according to any ofEmbodiments 1-42, in the form of a roll.

Embodiment 44. The insulation-retaining sheet according to any ofEmbodiments 1-43, wherein the insulation-retaining sheet has one or moreapertures formed therein.

Embodiment 45. The insulation-retaining sheet according to Embodiment45, wherein the one or more apertures have a longest dimension in therange of 1 inch to 6 inches.

Embodiment 46. The insulation-retaining sheet according to Embodiment 44or Embodiment 45, having a plurality of apertures along the length ofthe sheet, e.g., on 16 inch centers or on 24 inch centers.

Embodiment 47. A method of insulating one or more building cavities, themethod comprising:

-   -   providing one or more insulation cavities, each having an open        face defined at least in part by a plurality of building        members;    -   substantially enclosing the one or more insulation cavities with        an insulation-retaining sheet according to any of Embodiments        1-46 by affixing the insulation-retaining sheet to the plurality        of building members; and    -   blowing insulation into the one or more cavities.

Embodiment 48. The method of Embodiment 47, wherein the insulation isblown into each of the one or more cavities through an aperture in theinsulation-retaining sheet.

Embodiment 49. The method of Embodiment 47 or Embodiment 48, wherein themethod further comprises, after blowing the insulation into the one ormore cavities, covering one or more of (e.g., each of) the open zones.

Embodiment 50. The method of Embodiment 49, wherein each of one or moreof the open zones is covered by an adhesive tape.

Embodiment 51. The method of Embodiment 49 or Embodiment 50, whereineach of one or more of the open zones is covered by a separate strip ofvapor-retarding membrane.

Embodiment 52. The method of any of Embodiments 49-51, wherein each ofone or more of the open zones is covered by a separate strip ofmaterial.

Embodiment 53. The method of any of Embodiments 49-52, wherein theinsulation retaining sheet is an insulation-retaining sheet according toany of Embodiments 20-27, and wherein the method further includesaffixing the one or more flaps so as to cover one or more of the openzones.

Embodiment 54. The method of any of Embodiments 49-53, wherein thecovering of the one or more open zones is performed using one or more oftape, caulk and adhesive so as to substantially seal them.

Embodiment 55. The method of any of Embodiments 49-54, wherein theinsulating retaining sheet substantially improves the airtightness ofthe insulated cavity.

Embodiment 56. The method of any of Embodiments 49-55, furthercomprising installing a wallboard over the insulated cavity.

Embodiment 57. An insulated building cavity, the insulated buildingcavity comprising

-   -   a cavity closed off on one face by an insulation-retaining sheet        according to any of Embodiments 1-46; and    -   loose-fill insulation disposed in the cavity.

Embodiment 58. The insulated building cavity according to Embodiment 57,wherein each of one or more of the open zones of theinsulation-retaining sheet is covered, e.g., by a flap, by a separatestrip of material, by a separate strip of insulating material, or by astrip of adhesive tape.

Embodiment 59. The insulated building cavity according to Embodiment 58,wherein the insulation-retaining sheet acts as an air barrier andimparts substantial airtightness to the insulated building cavity.

What is claimed is:
 1. An insulation-retaining sheet having a top edgeand an opposed bottom edge, and a first side edge and an opposed secondside edge, the insulation-retaining sheet comprising: a sheet of meshhaving an air permeability of at least 200 cfm per square foot, a topedge and an opposed bottom edge, and a first side edge and an opposedsecond side edge; and one or more strips of vapor-retarding membrane,each of the one or more strips of vapor retarding membrane each having atop edge and an opposed bottom edge, and a first side edge and anopposed second side edge, the one or more strips of vapor-retardingmembrane being laminated to the sheet of mesh, the first side edge eachof the strips of vapor-retarding membrane extending to the first sideedge of the sheet of mesh, the second side edge each of the strips ofvapor-retarding membrane extending to the second side edge of the sheetof mesh, wherein the insulation-retaining sheet has a plurality of openzones extending laterally from the first side edge of the sheet of meshto the second side edge of the sheet of mesh in which no vapor-retardingmembrane is laminated to the mesh.
 2. The insulation-retaining sheetaccording to claim 1, wherein the mesh is a fabric mesh.
 3. Theinsulation-retaining sheet according to claim 1, wherein thevapor-retarding membrane has a water vapor permeance of no more thanabout 1 Perm at 25% relative humidity, as tested by ASTM E96 at 23° C.,and a water vapor permeance of at least 2 perms at 75% relative humidityas tested by ASTM E96 at 23° C.
 4. The insulation-retaining sheetaccording to claim 1, wherein the vapor retarding membrane has one ormore of a) a water vapor permeance of no more than 5 perms at 45%relative humidity, and b) a water vapor permeance of at least about 5Perms at 95% relative humidity, both as tested by ASTM E96 at 23° C. 5.The insulation-retaining sheet according to claim 1, wherein thevapor-retarding membrane is a polymer sheet, a polymer laminate, orcomprises a sheet having a vapor-retarding coating formed thereon. 6.The insulation-retaining sheet according to claim 1, comprising in therange of 2-10 strips of vapor-retarding membrane.
 7. Theinsulation-retaining sheet according to claim 1, wherein the one or moreopen zones include a top open zone extending along the top edge of theinsulation-retaining membrane and a bottom open zone extending along thebottom edge of the insulation-retaining membrane.
 8. Theinsulation-retaining sheet according to claim 1, wherein the one or moreopen zones include one or more interior open zones extending across thesheet of mesh between its top edge and its bottom edge.
 9. Theinsulation-retaining sheet according to claim 1, wherein each of thestrips of vapor-retarding membrane is laminated to the sheet of meshsubstantially throughout its height.
 10. The insulation-retaining sheetaccording to claim 1, wherein the one or more strips of vapor retardingmembrane comprise one or more first strips of vapor retarding membrane,each having a top zone in a top-most portion of the first strip, the topzone extending from the first side edge to the second side edge of thefirst strip, the top zone being laminated to the sheet of mesh, and abottom zone in a bottom-most portion of the first strip adjacent the topportion of the first strip, the bottom zone extending from the firstside edge to the second side edge of the first strip, the bottom zonenot being affixed to the sheet of mesh, the bottom zone forming a flaphaving a bottom edge, a first side edge and an opposed second side edge.11. The insulation-retaining sheet according to claim 1, wherein each ofthe strips of vapor retarding membrane has a height of at least 15inches.
 12. The insulation-retaining sheet according to claim 1, whereineach of the open zones has a height in the range of 1-24 inches.
 13. Theinsulation-retaining sheet according to claim 1, wherein at least 5% ofthe area of the insulation-retaining sheet is open zones.
 14. Theinsulation-retaining sheet according to claim 13, wherein no more than30% of the area of the insulation-retaining sheet is open zones.
 15. Theinsulation-retaining sheet according to claim 1, wherein theinsulation-retaining sheet has one or more apertures formed therein. 16.A method of insulating one or more building cavities, the methodcomprising: providing one or more building cavities, each having an openface defined at least in part by a plurality of building members;substantially enclosing the one or more building cavities with aninsulation-retaining sheet according to claim 1 by affixing theinsulation-retaining sheet to the plurality of building members; andblowing insulation into the one or more building cavities such that theinsulation is retained in the cavity by the insulation-retaining sheet.17. The method of claim 16, wherein the insulation is blown into each ofthe one or more cavities through an aperture in the insulation-retainingsheet.
 18. The method of claim 16, wherein the method further comprises,after blowing the insulation into the one or more cavities, covering oneor more of the open zones.
 19. An insulated building cavity, theinsulated building cavity comprising a building cavity closed off on oneface by an insulation-retaining sheet according to claim 1; andloose-fill insulation disposed in the building cavity and retained inthe building cavity by the insulation-retaining sheet.
 20. The insulatedbuilding cavity according to claim 19, wherein each of one or more ofthe open zones of the insulation-retaining sheet is covered by a flap,by a separate strip of material, by a separate strip of insulatingmaterial, or by a strip of adhesive tape.